Stitched nonwoven webs

ABSTRACT

A non-woven continuous filament product and a method for producing said product which comprises deregistering a crimped tow of continuous filaments, spreading the deregistered tow to produce a web, cross-lapping the web into a batt and subsequently dimensionally stabilizing the batt by stitching, in the absence of a supporting fabric.

Unlted States Patent 1191 1111 3,819,469 Balch et al. June 25, 1974 STITCHED NONWOVEN WEBS 1,860,090 5/1932 Fowler 161/59 x 1 1 Ralph Bamchaflofle; George 5:253:33? 3/1322 23355133: ::::..T. l2 Walson, Davldsoni Herbe" 2,381,184 8/1945 Ripley 161/59 x Coates, Charlotte, all of NC. 2,790,208 4/1957 Smith 28/72.1 2,908,064 10/1959 Lauterbach et a1 161/80 [73] Asslgnee' Celmese cmporammNew York 3,016,581 1/1962 Smith 19/65 NY 3,260,640 7/1966 Owen 161/50 22 i Apr. 6 1970 3,395,065 7/1968 Owen, Sr. 161/50 [21 Appl. No.: 25,676

Primary Examiner-Marion E. McCamish 'f l Application Data Attorney, Agent, or Firm-Andrew F. Sayko, Jr. [63] Contmuation-in-part of Ser. No. 658,781, Aug. 7,

1961, Pat. No. 3,505,155.

[52] us. Cl 161/154, 19/65, 28/72, 57 ABSTRACT l61/5 161/5 16l/l53 A non-woven continuous filament product and a [51] Int. Cl 1532b 5/06 ethod for producing said product which comprises Field of Search 97, deregistering a crimped tow of continuous filaments, 1/ 1 2, 4, spreading the deregistered tow to produce a web,

66/85 A cross-lapping the web into a batt and subsequently dimensionally stabilizing the batt by stitching, in the ab- [56] References Cited sence of a supporting fabric.

UNITED STATES PATENTS Fowler 161/59 X 11 Claims, 3 Drawing Figures PAifiNTlinJunzslsm INVENTOR RALPH HY BALCH GEORGE A WATSON HERBERT w COATES BY ME 7% ATT NEY' 1 STITCHED NONWOVEN WEBS BACKGROUND OF THE INVENTION This is a continuation-in-part of application Ser. No. 658,781 filed Aug. 7, 1967, now U.S. Pat. No. 3,505,155 which is a continuation-in-part of application Ser. No. 325,254 filed Nov. 21, 1963, and application Ser. No. 501,105 filed Oct. 22, 1965, both now abandoned.

This invention relates to continuous filament nonwoven products and more particularly to products produced by dimensionally stabilizing a spread web of continuous filament deregistered crimped tow.

Non-woven fibrous products are well known in the art. Normally, such products are made from staple fibers but more recently, methods have been devised for producing various products from continuous filaments. As is well known, staple fiber non-Wovens by their very nature, are not possessed of any considerable inherent tensile strength in any direction and thus are ordinarily easily distorted and even destroyed unless specially reinforced. Even when reinforced, it has been found that staple fiber non-Wovens do not have the desired degree of stability and durability, because they not only tend to lose fibers through migration, but they are also inadequate in the ability to retain bulk, compressibility, resiliency and the like.

To avoid some of these drawbacks and disadvantages, it has previously been proposed to utilize continuous filaments. Various methods have been devised to produce non-woven sheet materials composed of continuous filaments. While such processes have various advantages for particular uses, certain disadvantages also accompany many of these processes. Particularly, most of such continuous filament processes are limited to production by the filament manufacturer and the resulting product cannot be readily changed subsequently by the manufacturer of the finished product if somewhat different physical characteristics of the fabric or sheet material are desired. Also, many of these processes rely upon melt adhesion of the fibers to bond each other while still in a relatively plastic condition. This type of bonding greatly limits certain bulk characteristics often desired in the end product.

It is an object of the present invention to provide a dimensionally stabilized, non-woven, deregistered, crimped, continuous filament product particularly suitable for a wide variety of end uses, particularly bulky products of an insulating and/or cushioning character. It is another object of the present invention to provide a method for producing such products. These and other objects will become apparent to those skilled in the art from a description of the invention which follows:

SUMMARY OF THE INVENTION In accordance with the invention a non-woven continuous filament product is produced comprising deregistering a tow of crimped continuous filament, spreading the deregistered tow to produce a web, crosslapping the web to form a batt and subsequently dimensionally stabilizing the batt by stitching to produce a non-woven continuous filament product.

The present invention is particularly suitable for the production of insulating material for quilted articles and cushioning material as well as fibrous sheet material suitable for clothing, pillows, carpets, carpet underlay pads, mattress pads, quilts, and the like.

While the web of deregistered tow, after crosslapping into a batt, may be stabilized by being secured to a supporting fabric either by stitching or bonding, it is a feature of the present invention that no supporting fabric is used. Consequently, the added weight and cost of such fabric are eliminated. Equally important, the diminution in porosity and tendency toward stiffness which would accompany use of a fabric support is of course avoided.

The starting continuous filament crimped tow may be deregistered or opened by any of the systems heretofore known. Especially good results are obtained when deregistration is effected by passage between at least two pairs of rolls with the downstream pair operating at a higher peripheral speed than the upstream pair, at least one of the four rolls being profiled; preferably, one roll of each pair is helically grooved. A suitable tow opening system is disclosed in U.S. Pat. No. 3,156,016.

The deregistered tow is spread laterally to a filmy web so that its weight per square yard is less than about 3 ounces. This further spreading is conveniently done by use of a pneumatic banding jet; because of the manner in which opening was achieved the web may be spread so thinly without development of large splits.

The web is next cross-lapped into a batt, i.e. laid onto a moving belt transversely to the direction of movement of the belt. The relative speed of the belt and the cross-lapping apparatus will determine the number of superposed layers of web and the angle which the general direction of the filaments of each layer makes with the longitudinal direction of the batt, i.e. the direction of the belt. This angle must be greater than 45 but less than 90, advantageously ranges from about 60 to less than 90 and preferably ranges from about to less than In going through the batt vertically, successive layers of filaments will be encountered with the general direction of one layer being at an angle to its neighbor; since each layers angle with the general batt direction is between 45 and 90, the angle between the directions of the successive layers ranges from greater than 0 to less than 90. The width of the batt may be substantial, being determined by the width of the moving belt; batts as wide as 60 inches or more can be processed readily. The weight of the cross-lapped batt may be built up to as much as 18 ounces or more per square yard, starting at less than 3 ounces per square yard for the web before crosslapping. Preferably, the weight of the batt is about 2 to 25 ounces per square yard.

The batt is then stabilized by being subjected to stitching in longitudinal direction at laterally spaced locations. This may be achieved by conventional sewing machines operating side-by-side or by a single multihead stitching machine, e.g. the Arachne machine, or a quilting machine which produces substantially parallel rows of stitching. The stitching lines are substantially parallel and preferably straight but they could also be wavy and/or slightly off parallel.

The stitches should be of a frequency of at least about 6 per inch but may vary in size from about 6 to 25 per inch. The stitches may be formed in conventional manner using standard sewing threads. It is possible, however, using sewing needles with barbs or needles like knitting needles to form the stitches without sewing threads. Instead, each needle on each stroke will catch one or more continuous filaments from the batt and will form a stitch with it.

The longitudinally extending lines of stitching are desirably spaced less than about 32 inches apart and preferably less than 24 inches apart. Further, there must be at least three rows of stitching through the batt to achieve the desired stability.

It is surprising that the batt possesses transverse dimensional stability notwithstanding the absence of a dimensionally stable supporting fabric or a bonding agent. If the stitched batt is grabbed at its opposite edges and pulled, it will lengthen somewhat due to temporary straightening of the crimps but, upon release, will return to no more than about I and generally closer to 100% of its original length. A web which has not been cross-lapped or which has been cross-lapped but not stitched will not return to anywhere near its original width upon tensioning and releasing, in the absence of a supporting fabric. Accordingly, the present invention provides stability even transverse to the rows of stitches, without sacrifice in weight or porosity.

Stitched batts so produced are useful wherever batts have heretofore been used and are especially useful in quilted articles such as winter jackets, housecoats, and the like, wherein the absence of a supporting fabric achieves economy and simplicity of manufacture with no sacrifice in performance, e.g. warmth, bulk and hand.

BRIEF DESCRIPTION OF THE DRAWINGS The invention will be more fully described by reference to the accompanying drawings in which:

FIG. 1 is a schematic illustration of a method of deregistering a continuous filament tow and subsequently spreading the tow into a web;

FIG. 2 is a schematic illustration of a method for cross lapping and stitching the product emerging from the apparatus of FIG. 1; and

FIG. 3 is an enlarged partial, sectional view of a quilted article made from the product of the apparatus of FIG. 2.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS Referring more particularly to FIG. 1, a band of crimped continuous filament tow 10 is drawn from a bale 12 through a banding jet l3. Banding jet l3 preconditions the tow for further processing by removing snags, false twists and the like and straightens and flattens the tow so that it may be more readily processed. From banding jet 13, the tow is passed around stationary tensioning bars 17 and 18 prior to passing into the two opening zone.

The tow is conveniently opened or deregistered to prepare it for one or more spreading stages, by subjecting it, while moving in a predetermined path, to a differential gripping action between a plurality of points spaced from one another both longitudinally and transversly in the path so that certain laterally spaced sections of the tow are positively gripped relative to other laterally spaced sections of the tow. Alternating with the grip sections are sections where the tow is not gripped at all or it is gripped at different relative points. In this manner there is produced a relative shifting of the adjacent filaments longitudinally along the tow whereby the crimps are moved out of registry with one another. The shifting action is a function of the differential positive gripping of the tow. Preferably, although not necessarily, the differential gripping action is such that a relative lateral displacement between adjacent filaments of the tow is also effected, so that the combination of two transverse filament movements brings about the complete opening of the tow.

Several methods for effecting the differential gripping action are known in the art as well as several different apparatuses for effecting differential gripping, which apparatus deregister the tow with varying degrees of success. A preferred apparatus and method is disclosed by Dunlap et a]. in US. Pat. No. 3,156,016.

Typically, the differential gripping is achieved by using at least one pair of rollers, one of which is smooth surfaced and the other-of which is patterned over its entire periphery. The most preferred apparatus comprises a plurality of such pair of rollers arranged in tandem wherein one of each pair of rollers comprises a smooth surfaced roll coated with a resilient material such as rubber, and the other roller has alternating lands and grooves. Preferably, the lands and grooves form helical threads of about 8 to 20 threads per inch.

It will be apparent that the opening of the tow for the purposes of the present invention may be effected by means differing from the threaded roll type of apparatus disclosed in the aforesaid Dunlap et al. patent, although this tow opening and crimp deregistering apparatus is preferred due to its high efficiency and its uniformity of operation.

If desired, the grooves may be discontinuous i.e. take the form of intermittent depressions in the surface of the roll, and may, for example, impart to the roll surface a checkerboard or other pattern of alternately raised and depressed areas. Both rolls of any one set could be grooved, if desired, although best results are achieved when but one roll is so grooved. The path of the tow in moving between the nips of successive roll sets is horizontal in the Dunlap et a1. disclosure but can be made vertical if desired.

Thus, the tow is passed through the nip of a pair of rollers 19 and 21 prior to being passed through a second pair of rolls 22 and 23. In the most preferred embodiment, rolls l9 and 23 are patterned rolls such as threaded steel rolls and rolls 21 and 22 are resilient surfaced rolls.

Each pair of rolls is individually driven at a predetermined controlled speed. Generally, only one roll of each pair is positively driven while the other is in yieldable compressive contact with the driven roll and rotates due to the passing of the tow between the rollers. The differential gripping and deregistering action is produced by driving the second pair of rollers at a faster rate of speed than the first pair. Thus, the second pair of rollers is typically driven at a rate of about l.l to about 8 times and more preferably, at a rate of about 1.2 to about 3 times that of the first pair.

On leaving the deregistration zone, the crimp in the tow is out of registry with adjacent filaments.

After deregistering the tow, the tow is subjected to one or more spreading stages. Various spreading means can be used to spread the deregistered tow into a uniform web. Such means include mechanical spreading bars, diverging belts, air jets and the like. The most preferred means is an air jet. Using such spreading means, the tow can be spread into a web of relatively great width ranging up to about inches or more depending on the denier and number of filaments of the tow being spread. Because the most preferred means of spreading is by use of an air jet, the invention will be described more particularly with reference to air spreading although it is to be understood that other types of spreaders can be used.

The tow passing from the deregistration zone is thus passed through a first spreader 24. The tow is pulled through the spreader 24 by the action of driven rollers 36 and 37 about which tow is S wrapped. In passing through spreader 24, the tow is spread about 2 to 4 times the width of the tow exiting from the deregistration zone. As is often preferred in the present invention, the tow is preferably again spread in a second spreader 38 wherein the spread band is again spread to 2 to 4 times the width of the web drawn through rollers 36 and 37. Again the web is drawn through spreader 38 by means of another set of driven rollers 39 and 41. Thus, the spreading action preferably spreads the tow into a web at least twice the original width of the tow and more preferably at 2 to about 10 times the original tow width to produce a lightweight web of less than about 1 ounce per square yard. More preferably, webs in the weight range of about 0.005 to to 0.5 ounces per square yard and most preferably of about 0.01 to about 0.25 ounce per square yard are readily produced.

From rolls 39 and 41, the tow falls in a freely hanging shallow catenary 42 onto a horizontal moving surface of a wide endless belt 43. Idler roll 44 mounted on lever arm 46 pivoted at 47, extends across the full width of the web on belt 43. The idler roll serves to bring the tow web into firm contact with belt 43, to define the shape and position of catenary 42 and also to keep any loose ends in the catenary portion from being drawn around roller 41.

The spread web is then in condition to be cross lapped and dimensionally stabilized to form a more useful end product. As will be readily recognized, the cross-lapped web has some stability in the width direction along the general direction of the filaments but the stability in the longitudinal direction is extremely low. Thus, applying a tensile force across the width of the cross-lapped web will result in stretching, depending on the fiber used, with some recovery. When the tensile force is applied, the angle between the filament directions of successive layers is decreased and the filaments of all layers then lay in substantially the same direction. This narrowing of the angle between layers causes deformation of the cross-lapped web, i.c. increased length and decreased width. It is the stabilization of this angle by stitching which is the principal factor in stabilizing the cross-lapped web across its width.

By applying a tensile force along the length of the web, comparatively little resistance will be noted and a relatively low recovery will result. Thus, the web can be readily split in this manner thus losing its integrity as a web. Splitting or stretching of a stitched crosslapped web is limited by the stitching because the length of the web can be no greater than the length of the stitching.

The present invention is useful with all continuous filament materials which have been crimped prior to deregistration. The process is particularly useful with filaments of polyethylene terephthalate polyester and cellulose acetate of the usual acetyl content of about 54 to 55 percent calculated as acetic acid. However, the invention is also equally applicable to other tows such as those made of other polyesters such as polyesters of /30 isophthalic and terephthalic acids and other glycols such as dimethylolcyclohexane; linear super polyamides such as nylon 6 and nylon 66; polyacrylonitrile and copolymers of acrylonitrile; olefinic polymers and copolymers such as isotactic polypropylene; other organic derivatives of cellulose such as esters and/or ethers of cellulose, for example cellulose propanate and cellulose acetate propanate and the like; highly esterified cellulose containing less than 0.29 free hydroxyl groups per anhydroglucose units such as cellulose triacetate, rayon and the like.

The number of filaments in the starting tow can vary within wide limits and may range up to as high as about one million with a denier per filament as high as about 25, that is, in the range of about 0.5 to about 25 or more, preferably in the range of l to 20 denier per filament. The number of crimps per inch of tow may range up to as high as about 80, but for most end products a crimp of about 3 to 50 crimps per inch, preferably about 3 to 20 crimps per inch of starting tow are found to be exceptionally satisfactory.

Referring more specifically to FIG. 2, the spread web can be unified or dimensionally stabilized without recourse to auxiliary supporting sheet materials. Accordingly, articles such as bedspreads, housecoats, and the like, wherein the absence of a supporting fabric achieves economy and simplicity of manufacture with no sacrifice in performance.

The opened, spread web 10 carried on belt 43 of FIG. 1 is transferred to a conventional camel back crosslapper, partially shown at 48 in FIG. 2. The tow 10 now in the form of a web is laid transversely across a belt 49, the tow layer being reciprocated across the belt. Because the belt 49 is moving to the right, the general direction of the filaments in the web is not perpendicular to the belt direction of advance but rather makes an angle therewith of about In this manner the batt builds up in thickness so that at any given downstream location on belt 49 the batt will be several layers thick. The batt then passes beneath a sewing mechanism 50 which is provided with multiple sewing heads forming three rows of parallel stitches 51 in the batt. The stitched batt may be rolled up or cut into predetermined lengths for use in making quilted articles such as shown in FIG. 3.

In FIG. 3 there is shown a portion of a quilted article 52 such as a bedspread or housecoat. The article 52 comprises top and bottom fabrics 53 and 54, respectively, between which is sandwiched the batt comprising opened tow 10 with stitches 51 stabilizing it. The whole structure is held together by diamond stitch lines 55.

Actually the stitch lines 55 can be further apart than usual since the continuous nature of the filaments, together with their dimensional stabilization, prevent the fiber migration or shifting of the batt which oftentimes occurs with staple fiber structures or with continuous filament structures if unstabilized. The product is free of the stiff hand which occurs when bonding agents are used for dimensional stabilizing. Neither is there the added weight and cost which attends use of a fabric as a support to which battings have heretofore been affixed during initial formation.

If desired, the cross-lapped batt may be grasped by mechanical hands during the stitching, the hands serving to apply tension.

The tensioning is preferably in an amount insufficient to remove the crimp from the fibers but sufficient to stretch the fibers to their full length. This pretensioning has been found to unexpectedly increase the loft or bulkiness to the end product. Such bulkiness increases the cushioning and insulating value of the final product.

The following example illustrates how the invention may be practiced.

EXAMPLE A polyester continuous filament tow having a total denier of 220,000, a denier per filament of 5.0 and about 8 crimps per inch is processed through a tow opening and crimp deregistering apparatus of the threaded roll type disclosed in the hereinbefore mentioned Dunlap et al. patent, said apparatus having a first pair of rolls operating at a speed of about 21.3 yards per minute, and a second pair of rolls operating at a speed of about 30 yards per minute. The resulting tow is in the form of a band about 12 inches wide. Thereafter, the opened tow is passed under a tension of approximately 8 ounces over a spreading device consisting of 2 curved bars. The spread tow band is approximately 40 inches wide and has a base weight of about 0.8 ounces per square yard. The web so formed is fed to a came] back cross-layer which deposits the web across a moving belt to form an 80 angle between the general filament direction and the belt direction. The web is laid 48 inches wide, building up to a batt weighing about 8 ounces per square yard. The batt is stitched longitudinally in three parallel rows spaced 16 inches apart and 8 inches from each edge. The resulting stabilized batt is sandwiched between a decorative cover fabric and a lining fabric and the laminate is quilted in a diamond pattern wherein the diamonds have 60 apex angles and are 2 inches on a side.

While there have been described various embodiments of the present invention, the method described is not intended to be understood as limiting the scope of the invention as it is realized that changes therein are possible. It is intended that each element recited in the following claims is to be understood as referring to all equivalent elements for accomplishing substantially the same results in substantially the same or equivalent manner. It is intended to cover the invention broadly in whatever form its principles may be utilized.

What is claimed is:

l. The process which comprises cross-lapping an opened web of longitudinally extending crimped deregistered continuous filaments to form a batt of successive layers of said web, with the angle between the direction of the filaments in said layers and the longitudinal direction of the batt ranging from greater than 45 to less than 90, with the angle between directions of the filaments of successive layers ranging from greater than to less than 90 and, in the absence of a supporting fabric, forming at least three spaced longitudinally extending substantially parallel rows of stitching through the batt and stabilizing the angle between the filament directions of successive layers in said batt.

2. The process of claim 1 wherein the stitches are formed by a multi-head stitching machine.

3. The process of claim 2 wherein the stitching machine has needles which reciprocate through the batt and, without supply of sewing thread, form stitches by catching filaments from the batt.

4. The process of claim 1 wherein at least three rows of stitching are provided, spaced apart about less than 24 inches.

5. The process of claim 1 wherein the batt has a weight of about 2 to 25 ounces per square yard.

6. The process of claim 1 wherein the stitching is at a frequency of from about 6 to 25 stitches per inch.

7. The process of claim 1 wherein the web is produced by passage of the unopened tow between at least two pairs of rolls with the downstream pair operating at a higher peripheral speed than the upstream pair, at least one of the four rolls being profiled.

8. The process which comprises continuously passing a tow of crimped continuous filaments lightly adhered to one another through two pairs of rolls, one roll of each pair being helically grooved, the downstream rolls operating at a higher peripheral speed than the upstream rolls, whereby the filaments form a web wherein the crimped filaments are deregistered, spreading the web to expand its lateral dimension, further spreading the web laterally so that its weight per square yard is less than about 3 ounces, cross-lapping the web to form a batt weighing about 2 to 25 ounces per square yard, the angle between the direction of the filaments and the longitudinal direction of the batt ranging from greater than 45 to less than without a supporting fabric passing the batt below a multi-head stitching machine, forming through the batt at least three longitudinally extending parallel rows of stitching spaced apart about 6 to 12 inches and stabilizing the angle between the filament directions of successive layers.

9. A dimensionally stable batt comprising a multilayered web made up of successive cross-lapped layers of deregistered crimped continuous filaments, the batt weighing about 2 to 25 ounces per square yard, being free of supporting fabric, and being dimensionally stabilized by at least three generally parallel longitudinal rows of stitching spaced less than about 24 inches, the angle between the direction of the filaments and the general stitch direction of the batt ranging from greater than 45 to less than 90 and the angle between successive layers of said web being substantially stable and ranging from greater than 0 to less than 90.

'10. The batt of claim 9 wherein the stitching has a frequency of from about 6 to 25 stitches per inch.

11. The batt of claim 9, wherein the deregistered continuous filament web exhibits a weight of about 0.5 to about 1.0 ounces per square yard. 

1. The process which comprises cross-lapping an opened web of longitudinally extending crimped deregistered continuous filaments to form a batt of successive layers of said web, with the angle between the direction of the filaments in said layers and the longitudinal direction of the batt ranging from greater than 45* to less than 90*, with the angle between directions of the filaments of successive layers ranging from greater than 0* to less than 90* and, in the absence of a supporting fabric, forming at least three spaced longitudinally extending substantially parallel rows of stitching through the batt and stabilizing the angle between the filament directions of successive layers in said batt.
 2. The process of claim 1 wherein the stitches are formed by a multi-head stitching machine.
 3. The process of claim 2 wherein the stitching machine has needles which reciprocate through the batt and, without supply of sewing thread, form stitches by catching filaments from the batt.
 4. The process of claim 1 wherein at least three rows of stitching are provided, spaced apart about less than 24 inches.
 5. The process of claim 1 wherein the batt has a weight of about 2 to 25 ounces per square yard.
 6. The process of claim 1 wherein the stitching is at a frequency of from about 6 to 25 stitches per inch.
 7. The process of claim 1 wherein the web is produced by passage of the unopened tow between at least two pairs of rolls with the downstream pair operating at a higher peripheral speed than the upstream pair, at least one of the four rolls being profiled.
 8. The process which comprises continuously passing a tow of crimped continuous filaments lightly adhered to one another through two pairs of rolls, one roll of each pair being helically grooved, the downstream rolls operating at a higher peripheral speed than the upstream rolls, whereby the filaments form a web wherein the crimped filaments are deregistered, spreading the web to expand its lateral dimension, further spreading the web laterally so that its weight per square yard is less than about 3 ounces, cross-lapping the web to form a batt weighing about 2 to 25 ounces per square yard, the angle between the direction of the filaments and the longitudinal direction of the batt ranging from greater than 45* to less than 90*, without a supporting fabric passing the batt below a multi-head stitching machine, forming through the batt at least three longitudinally extending parallel rows of stitching spaced apart about 6 to 12 inches and stabilizing the angle between the filament directions of successive layers.
 9. A dimensionally stable batt comprising a multi-layered web made up of successive cross-lapped layers of deregistered crimped continuous filaments, the batt weighing about 2 to 25 ounces per square yard, being free of supporting fabric, and being dimensionally stabilized by at least three generally parallel longitudinal rows of stitching spaced less than about 24 inches, the angle between the direction of the filaments and the general stitch direction of the batt ranging from greater than 45* to leSs than 90* and the angle between successive layers of said web being substantially stable and ranging from greater than 0* to less than 90*.
 10. The batt of claim 9 wherein the stitching has a frequency of from about 6 to 25 stitches per inch.
 11. The batt of claim 9, wherein the deregistered continuous filament web exhibits a weight of about 0.5 to about 1.0 ounces per square yard. 